Ferroli Domina 102 Installation, Servicing And User Instructions Manual

Appr. nr. B99.06 A - CE 0461 AU 0431

DOMINA 102

COPPER WALL-MOUNTED COMBINATION,

GAS FIRED BOILER FOR CENTRAL HEATING

AND DOMESTIC HOT WATER PRODUCTION,

FAN ASSISTED, ROOM SEALED COMPARTMENT,

ELECTRONIC FLAME IGNITION AND CONTROL

3543837/0 - 06/2001

INSTALLATION, SERVICING AND

USER INSTRUCTIONS

G.C. NO: 47-267-24

DOMINA 102

2

CE MARK

CE mark documents that the Ferroli gas appliances comply with the requirement contained in

European directives applicable to them.

In particular, the appliances comply with the following CEE directives and the technical speciﬁ cations

provided from them:

• Gas appliances directive 90/396

• Efﬁ ciencies directive 92/42

• Low tension directive 73/23 (modiﬁ ed from the 93/68)

• Electromagnetic compatibility directive 89/396 (modiﬁ ed from the 93/68)

Year 2000 Compliance Declaration

We will guarantee that this products is altogether suitable for the data change in the Year

2000 (boiler has no dependence from date change) and that no disruptions will occur which is

caused by this product.

IMPORTANT

Your "benchmark" Installation, Commissioning and Service Record Log Book will be enclosed

in your customer information pack.

"This record must be completed and left with the end user"

"All CORGI Registered Installers carry a CORGI ID card and have a registration number. Both should

be recorded in your central heating log book. You can check the installer's CORGI registration

by calling CORGI on 01256 372300".

Ferroli is a member of the Benchmark initiative and fully supports the aims of the programme. Benchmark

has been introduced to improve the standards of installation and commissioning of central heating

systems in the UK and to encourage the regular servicing of all central heating systems to ensure safety

and efﬁ ciency. Please see installation and servicing guidelines.

INDEX

1. DESCRIPTION........................................................................................................................................ 3

2. TECHNICAL AND DIMENSIONAL CHARACTERISTICS....................................................................... 4

3. INSTALLATION DETAILS........................................................................................................................ 9

4. COMMISSIONING AND TESTING............................................................................................... 22

5. ADJUSTMENT AND GAS CONVERSION ........................................................................................... 23

6. MAINTENANCE AND CLEANING ..................................................................................................... 25

7. REPLACEMENT OF PARTS .......................................................................................................... 27

8. FAULT FINDING.................................................................................................................................. 32

9. ELECTRICAL AND FUNCTIONAL SCHEME....................................................................................... 39

10. USER INSTRUCTIONS ....................................................................................................................... 41

DOMINA 102

3

1. DESCRIPTION

1.01 Introduction

The Domina 102 is deﬁ ned as a “room sealed” combination boiler, all air required for combustion is taken from

outside the room in which it is installed. It is a new high performance gas ﬁ red heat generator for central heating and

domestic hot water production. A special feature of this boiler is its built-in electronic ﬂ ame ignition and control unit

making burner operation completely automatic and safe. The main components are as follows:

• Copper heat exchanger consisting of three ﬁ nned tubes speciﬁ cally shaped for high efﬁ ciency.

• There are three copper coils inserted in the three heating circuit tubes. These represent the domestic hot water heat

exchanger. Their shape and high exchange surface area enable the full output of the boiler to be absorbed.

• Ceramic ﬁ bre insulated combustion chamber

• 16 stainless steel bladed burners speciﬁ cally designed for this boiler.

• Fan for discharge of combustion products and intake of combustion air.

• Differential air pressure switch. For safety reasons, this ensures the burner ignites only when the fan

is functioning correctly.

• Hermetically sealed compartment made from corrosion-resistant steel enclosing the above components.

• Combination gas safety valve with modulator, complete with pressure stabiliser.

• Flowmeter giving the domestic hot water circuit precedence over the central heating circuit.

• Pressure relief valve for the central heating circuit set to open at 3 bar.

• Built-in Expansion vessel.

• Variable speed pump.

• Central heating ﬂ ow temperature adjustment thermostat.

• Domestic hot water ﬂ ow temperature adjustment thermostat.

• Central heating limit thermostat.

• Overheat safety thermostat.

• Electronic control unit for automatic ﬂ ame ignition and control.

• Central heating low water pressure cut off switch.

• Domestic hot water ﬂ ow temperature sensor.

• Central heating ﬂ ow temperature sensor.

• Safety bracket

1.02 Instructions and regulations

Assembly, installation, ﬁ rst start up and maintenance must be carried out by competent persons only, in accordance

with all current technical regulations and directives.

C.O.S.H.H.

Materials used in the manufacture of this appliance are non hazardous and no special precautions are

required when servicing.

Related Documents

This appliance must be installed strictly in accordance with these instructions.

The Gas Safety Regulations (Installations & Use) 1996.

The Local Building Regulations.

The Building Regulations.

The Buildings Standards (Scotland - Consolidated) Regulations.

British Standards Codes of Practice:

B.S. 7593 1992 TREATMENT OF WATER IN DOMESTIC HOT WATER CENTRAL HEATING SYSTEMS

B.S. 5546 1990 INSTALLATION OF HOT WATER SUPPLIES FOR DOMESTIC PURPOSES

B.S. 5440 Part 1 2000 FLUES

B.S. 5440 Part 2 1989 AIR SUPPLY

B.S. 5449 1990 FORCED CIRCULATION HOT WATER SYSTEMS

B.S. 6798 1987 INSTALLATION OF GAS FIRED HOT WATER BOILERS

B.S. 6891 1989 GAS INSTALLATIONS

B.S. 7671 1992 IEE WIRING REGULATIONS

B.S. 4814 1990 SPECIFICATION FOR EXPANSION VESSELS

B.S. 5482 1994 INSTALLATION OF LPG

Model Water Bye Laws

For Northern Ireland the rules in force apply

DOMINA 102

4

Fig. 1

2. TECHNICAL AND DIMENSIONAL CHARACTERISTICS

2.01 Technical information

Domina 102 boilers are central heating and domestic hot water heat generators and are produced as standard

to function with natural gas or liquid petrolium gas converted.

Key

1 - 3/4" central heating ﬂ ow outlet

2 - 1/2" domestic hot water ﬂ ow outlet

3 - 1/2 “ gas inlet

4 - 1/2" domestic hot water inlet

5 - 3/4" central heating return inlet

363

75

15 430

760

15

692

460

36 155

95 54

60

2

53

1

60

189

175

13 5

2

Top view

4

202

150

Ø80 Ø80 Ø80

120 12070

Bottom view

DOMINA 102

5

N.B. - The gas pressures at the burner and gas ﬂ ows during the central heating phase given in the table refer

to nominal boiler output. To reduce this output (where necessary), gas pressure must be reduced until the

required output level is reached (see ﬁ gures 4 and 5).

During domestic hot water production, gas pressures to the burner must correspond to the maximum

output given in table for the type of gas.

Gas pressure must be adjusted during maximum draw-off of domestic hot water.

• Maximum working temperature for central heating ﬂ ow: 85°C

• Maximum temperature of domestic hot water: 55°C, adjustable between 40°C and 55°C.

• Minimum domestic cold water pressure required for 95% heat input:

- Flow restrictor ﬁ tted (standard) - 1,2 bar;

- Flow restrictor removed - 0,5 bar

Technical Data

MODEL Heat output Heat input

Net

Domestic hot

water heat

input

Gross

Boiler water

contents

Domestic hot

water circuit

contents

kW kW kW kW kW Litres Litres

Domina 102 30,0 12,7 33,1 14,5 30,0 1,5 0,8

MODEL

Connections Expansion vessel

Max. working

pressure

central

heating

circuit

Max.

working

pressure hot

water circuit

12345Capacity Pre-pressurising

value

ØØØØØLitres bar bar b

Domina 102 3/4” 1/2” 1/2” 1/2” 3/4” 10 1 3 6

MODEL

Main injectors (mm) Gas flow rates to main burners

for central heating Gas valve

Ø1/2”

G20 - NG G31 - LPG G20 - NG G31 - LPG

ØØ m

3/h kg/h

Domina 102 16x1,25 16x0,75 3,5 2,6 H. V K4105G

MODEL

Gas supply pressures

working Gas pressure at main burner for central heating

Safety valve

G20 - NG G31 - LPG G20 - NG G31 - LPG

min. max. min. max.

mbar mbar mbar mbar mbar mbar bar

Domina 102 20 31 2,5 13,0 7,0 35,5 3

MODEL

Domestic hot

water production

with ∆t 30°C

Domestic hot

water production

with ∆t 35°C

Max. working

pressure domestic

hot water Protection

level

Weight

G20 - NG G31 - LPG

l/min. l/min. mbar mbar kg

Domina 102 14,3 12,3 13,0 35,5 IP44 48

DOMINA 102

6

2.03 Boiler water ﬂ ow diagram2.02 Boiler main components

Key

5 Room sealed compartment

7 Gas inlet

8 Domestic hot water outlet

9 Domestic hot water inlet

10 Central heating ﬂ ow outlet

11 Central heating return inlet

14 Safety valve

16 Fan

19 Combustion chamber

20 Burner assembly

21 Main injector

22 Burner

26 Combustion chamber insulation

27 Copper heat exchanger for central

heating and domestic hot water

28 Flue collector from heat exchanger

29 Internal ﬂ ue exit

32 Central heating pump

34 Central heating ﬂ ow temperature sensor

36 Automatic air vent valve

Fig. 2

Fig. 3

818222

29 43187

RESET

OFF

ON

0

5

1

234

6

bar

98 63 157 145

°C°C

62

IN OUT

MIN

GRUNDFOS

FERROLI

114

34

20

21

90

50

16

28

32

26

19

49

132

5

56

27

91

10 8 784 85 44 136

14 42 9 11

36

OUT

IN

MIN

AIR

IN

AIR

IN

FLUE

OUT

C.H.

OUT D.H.W.

OUT GAS

IN D.H.W.

IN C.H.

IN

42 Domestic hot water ﬂ ow

temperature sensor

43 Air pressure switch

44 Gas valve

49 Safety overheat thermostat

50 Central heating ﬂ ow limit thermostat

56 Expansion vessel

62 Time clock (option)

63 Central heating temperature adjustment

81 Ignition electrode

82 Sensor electrode

84 Primary gas valve solenoid

85 Secondary gas valve solenoid

90* Flue outlet test point

91* Air test point

98 On/Off/Reset switch

114Low water pressure cut off switch

132 Flue gas deﬂ ector

136Flow meter

145Central heating pressure gauge

157Domestic hot water temperature adjustment

187Restrictor

* For use with ﬂ ue gas analyser

DOMINA 102

7

2.05 Pump characteristics

The pump head available for circulating the water

is given in ﬁ g. 6.

N.B. - The pump is factory set at position 3. The pump

is a Grundfos type 15-50 UPS series.

Grundfos Pump performance graph

Note - Minimum ﬂ ow through boiler heat exchanger at

any time should not fall below 6 litres per minute.

If the total volume of water in the system exceeds 40

litres an additional expansion vessel must be ﬁ tted to

the central heating return pipe.

Pump performance curve Grundfos UPS 15-50

Fig. 6

1 2 3 Speed settings

A Boilers pressure drop

B Available pump head C.H.

2.04 Central heating adjustment (not normally required)

To adjust boiler heat input (thus also regulating heat output to the central heating water) simply adjust the main

burner via the electronic control board (ﬁ g. 4, 5 and see paragraph 5.04 page 24).

The diagrams indicate the variation in heat output to the water as burner working pressure is varied.

Adjusting boiler output to the actual requirements of the central heating system will minimise boiler cycling thus saving

fuel, varying the output has virtually no effect on the efﬁ ciency and combustion characteristics of the boiler.

Diagram of pressures

and outputs with Natural gas

Fig. 4Fig. 5

Diagram of pressures and outputs

with LPG (Propane)

2

3

4

5

6

7

8

9

10

11

12

13

12 13 14 15 16 17 18 19 20 21 22 23 24

11 12 13 14 15 16 17 18 19 20 21

kW

kcal/h

x 1000

mbar

14

25 26 27 28 29 30 31

22 23 24 25 26

kW

kcal/h

X 1000

m

b

ar

18 19 20 21 22 23

5

10

15

20

25

30

35

12 13 14 15 16 17

11 12 13 14 18 19 2015 16 17

25 26 27 28 29 3024

21 25 2622 23 24

DOMINA 102

8

SIZING OF ADDITIONAL EX PANSION VESSELS:

Deduct from the value given in the table the 10

litre vessel supplied.

Note:

1. Fill C.H. installation to min. 1.5 bar.

2. Expansion vessel must be ﬁ tted to central

heating return pipe.

3. The standard 10 litre expansion vessel is

charged to 1 bar.

4. The additional expansion vessel should be

charged to 1 bar.

SAFETY VALVE

SETTING (bar)

VESSEL CHARGE

PRESSURE (bar)

INITIAL SYSTEM

PRESSURE (bar)

TOTAL WATER

CONTENT of SYSTEM

3.0

0.5 1.0 1.5

1.0 1.5 2.0 1.5 2.0 2.0

EX PANSION VESSEL VOLUME (litres)

LITRES

25 3.5 6.5 13.7 4.7 10.3 8.3

50 7.0 12.9 27.5 9.5 20.6 16.5

75 10.5 19.4 41.3 14.2 30.9 24.8

100 14.0 25.9 55.1 19.0 41.2 33.1

125 17.5 32.4 68.9 23.7 51.5 41.3

150 21.0 38.8 82.6 28.5 61.8 49.6

175 24.5 45.3 96.4 33.2 72.1 57.9

200 28.0 51.8 110.2 38.0 82.4 66.2

0.140 0.259 0.551 0.190 0.412 0.33

For syst. volumes other than

those given above, mult. the syst.

volume by the factor across

Fig. 7

Pressure loss diagram

m |h

3

Q

8

7

6

5

4

3

2

1

00.5 1.5 2.512

Hmbar x 100

DOMINA 102

9

3. INSTALLATION DETAILS

Gas Safety (Installation & Use) Regulations: 1996

In the interest of safety, it is the law that all gas appliances are installed by a competent person in accordance

with the above Regulations, Building Regulations/Building Standards Scotland, Codes of Practice, current I.E.E.

Regulations and the byelaws of the Local Water Undertaking. Failure to comply with the Regulations may lead to

prosecution; it is your responsibility to ensure that the law is complied with.

N.B. For Northern Ireland the rules in force apply.

Important - If the boiler is to be ﬁ tted in a timber framed building it should be ﬁ tted in accordance with the Institute of

Gas Engineers document IGE/UP/7. If in doubt advice should be sought from the Local Supplier.

Location of Boiler

The installation of the Domina 102 must be on a suitable non-combustible load bearing wall which will provide

an adequate ﬁ xing for the boiler mounting safety bracket assembly. The location should be in an area where

the water pipes will not be subjected to frost conditions. In siting the combination boiler the following

limitations must be observed:

The combination boiler may be installed in any room or internal space, although particular attention is drawn

to the requirements of the current I.E.E. wiring regulations and in Scotland the electrical provisions of the

building regulations applicable in Scotland, with respect to the installation of the combination boiler in a room

or internal space containing a bath or shower.

Where a room sealed appliance is installed in a room containing a bath or shower any electrical switch

or appliance control utilising mains electricity must be situated so that it cannot be touched by a person

using the bath or shower.

Air Supply

The room or compartment in which the boiler is installed does not require a purpose provided vent when

using the standard concentric ﬂ ue.

Flue System

The boiler allows the ﬂ ue outlet to be taken from the rear of the boiler, from either side or vertically.

A standard ﬂ ue length of 0.75 metres is provided. Alternative lengths of two or three metres can be supplied

(equivalent to wall thicknesses of up to 565, 1815 and 2815mm for rear ﬂ ues, deduct 91mm plus distance from side

wall for side outlet ﬂ ues). It is absolutely essential, to ensure that products of combustion discharging from the

terminal cannot re-enter the building, or enter any adjacent building, through ventilations, windows, doors,

natural air inﬁ ltration or forced ventilation/air conditioning.

Gas Supply

If necessary the local Gas supplier should be consulted, at the installation planning stage, in order to establish

the availability of an adequate supply of gas.

An existing service pipe must not be used without prior consultation with the Local Gas supplier.

A gas meter can only be connected by the Local Gas supplier, or by a Local Gas suppliers Contractor.

Installation pipes should be ﬁ tted in accordance with BS6891-1988.

Appliance inlet working pressure must be 20mbar MINIMUM, for NG and 37 mbar minimum for LPG.

Pipework from the meter to the combination boiler must be of an adequate size.

The boiler requires 3.5 m3/h of natural gas, and 2.60 kg/h of LPG.

Do not use pipes of a smaller size than the combination boiler inlet gas connection.

The complete installation must be tested for gas soundness and purged as described in BS6981-1988. All pipework

must be adequately supported. An isolating gas valve is provided and should be ﬁ tted on the boiler gas inlet.

Please wait 10 minutes when lighting from cold before checking gas rate. Gas pressures should be checked after

the boiler has operated for 10 minutes to reach thermal equilibrium.

Water System

Note - the boiler is designed for sealed systems only and must NOT be used on open vented systems.

DOMINA 102

10

Central Heating

Detailed recommendations are given in BS6798, BS5449, BS6700 and CP342 Part 2. Pipework not forming part

of the useful heating suface should be insulated to prevent any heat losses or possible freezing (i.e. in roof spaces

or ventilated underﬂ oor spaces). Drain taps should be positioned at the lowest point of the system in accessible

locations to permit the whole system to be drained down. The drain taps should be in accordance with BS2879. Copper

tubing to BS2871, Part 1 is recommended for water carrying pipework. Pipework in horizontal runs should have a

gradient where possible to facilitate the removal of air. Ensure that the boiler heat exchanger is not a natural point for

air collection. A typical heating system with domestic hot water circuit is illustrated in ﬁ g. 8.

Important - If thermostatic radiator vales are ﬁ tted a bypass must be ﬁ tted to ensure a minimum ﬂ ow rate through

the boiler of 6 l/min. The bypass should be ﬁ tted as far as possible from the boiler.

Make Up Water

Provision must be made for replacing water lost from the sealed system. Reference should be made to BS6798,

for methods of ﬁ lling and making up sealed systems. There must be no direct connection between the boiler's

central heating system and the mains water supply. The use of mains water to charge and pressurise the system

directly, is conditional upon the Local Water Byelaws. Again any such connection must be disconnected after use.

A typical temporary ﬁ lling loop is shown in ﬁ g. 9.

Domestic Hot Water

Always ﬁ t a scale reducer in "hard water areas" (18 clarke degrees or over)". A 15mm copper connection point on the

boiler for attaching to the main supply is provided. The maximum domestic water pressure for the inlet supply is 10 bar

(145 P.S.I.). If the cold mains supply exceeds 5 bar (72 P.S.I.), a water governor or pressure reducing valve must be

ﬁ tted by the installer into the mains supply in an inconspicuous but accessible position preferable between 3 and 5 metres

(10-16ft) before the appliance. Such a valve must be approved by the Water Research Council.

Attention - is drawn to the Model Water Byelaws.

Fittings manufactured from duplex (alpha-beta) brass are not acceptable for underground use and certain water

undertakings will not accept their use above ground.

Ensure all pipework is adequately supported

NOTE: A bypass must be ﬁ tted as far as possible

from the boiler if thermostatic radiator valves are

ﬁ tted thoughout.

Fig. 8

Gas

Cold water

Additional expansion

vessel C.H. (if required)

Filling

point C.H.

Bypass

Key

1. Filling point C.H.

2. Temporary connection

3. Cold water supply Fig. 9

DOMINA 102

11

Terminal Position

Fig. 11

CLEARANCES:

* 600mm minimum clearance for servi-

cing access

460 5 min.5 min.

100 min.837

600* min.

760

200 min.

363 50 mm

Fig. 10

P

D, E

Q

l

BC

A

G

F

L

J

HH

K

N

MM

Q

Directly below an opening, air brick, (0-7 kW)

opening windows, etc. (>7-14 kW)

(>14-32 kW)

(>32-70 kW)

Above an opening, air brick, (0-7 kW)

opening windows, etc. (>7-14 kW)

(>14-32 kW)

(>32-70 kW)

Horizontally to an opening, air brick, (0-7 kW)

opening windows, etc. (>7-14 kW)

(>14-32 kW)

(>32-70 kW)

Below gutters, soil pipes or drain pipes

Below eaves

Below balconies or car port roof

From a vertical drain pipe or soil pipe

From an internal or external corner

Above ground roof or balcony level

From a surface facing the terminal

(also see 6.1.2)

From a terminal facing the terminal

From an opening in the car port ( e.g. door,

window) into the dwelling

Vertically from a terminal on the same wall

Horizontally from a terminal on the same wall

From the wall on which the terminal is mounted

From a vertical structure on the roof

Above intersection with roof

Dimensions Terminal position

(kW input expressed in net)

Balanced flues room

sealed Open flues

Natural

draught Natural

draught

Fanned

draught Fanned

draught

Aa300 mm

600 mm

1500 mm

2000 mm

300 mm Not allowed 300 mm

Ba300 mm

300 mm

600 mm

300 mm Not allowed 300 mm

Ca300 mm

400 mm

600 mm

300 mm Not allowed 300 mm

D300 mm 75 mm Not allowed 75 mm

E300 mm 200 mm Not allowed 200 mm

F600 mm 200 mm Not allowed 200 mm

G300 mm 150 mmbNot allowed 150 mm

H600 mm 300 mm Not allowed 200 mm

I300 mm 300 mm Not allowed 300 mm

J600 mm 600 mm N/A 600 mm

K600 mm 1200 mm N/A 1200 mm

L1200 mm 1200 mm N/A 1200 mm

M1500 mm 1500 mm N/A 1500 mm

N300 mm 300 mm N/A 300 mm

ON/A N/A N/A 50 mm

PN/A N/A See Table 2

and Fig. 6b N/A

QN/A N/A See Table 2

and Fig. 4 150 mm

NOTE N/A = Not applicable

a In addition, the terminal should not be nearer than 150 mm (fanned draucht) or 300 mm (natural draught) to an opening in the building fabric formed for the purpose of accommodating

a built-in element such as a window frame, (see Figure C2). Separation distances are linked to the rated heat inputs as shown.

b This dimension may be reduced to 75 mm for appliances of up to 5 kW heat input.

Minimum dimensions of ﬂ ue terminal positions

DOMINA 102

12

3.01 Drilling Template (Top Flue Application)

Select suitable mounting position for boiler, using the template mark ﬂ ue outlet and boiler mounting points.

Drill two 10mm holes 90mm deep to accept the wall plugs, ﬁ t wall plugs. Fit two special wall plugs on the wall as

described in the ﬁ g. 12a. Fasten the wall bracket to the wall using an antitheft nut on the right side and a standard

nut (M8) on the left side. Mount the boiler on the wall bracket and ﬁ x using an antitheft nut on the left side and a

standard nut (M8) on the right side. Using a core drill cut a 118mm diameter hole for the ﬂ ue.

1. CH ﬂ ow (22 mm)

2. Safety Valve (15 mm)

3. Domestic hot water outlet (15 mm)

4. Gas supply (22 mm)

5. Domestic hot water inlet (15 mm)

6. CH return (22 mm) Fig. 12b

75

5 min

195 min

200 min

955 min

200

460 min

123 4 5 6

15 15

Ø3/4''Ø3/4'' Ø1/2''Ø1/2''Ø1/2''Ø1/2''

==

Ø120

jig bracket

Fig. 12a

DOMINA 102

13

3.02 Restrictor

For boiler operation, the restrictor supplied with the unit must be mounted following the instructions below.

Determine the correct size of ﬂ ue restrictor required. Before inserting the ﬂ ue gas duct in the boiler, check that

the restrictor ﬁ tted is correct and that it is correctly positioned (see ﬁ g. 13).

Holes Ø : 47 50 52

Ø

Fig. 13

Choice of restrictor:

• With concentric pipes: - up to 1m long + one bend, use the 52 mm restrictor.

- for ﬂ ue lengths over 1 metre, use no restrictor.

• With 2 pipe system: - Calculate the total ﬂ ow resistance of the air and ﬂ ue pipes in metres

(cap. 3.04.2)

- utilise the table shown below to choose the more suitable restrictor for

the ﬂ ow resistance calculated

RESTRICTOR FOR TWO PIPE SYSTEM

ON DOMINA 102

Total flow resistance

of flue system

Use

restrictor

size

minimum maximum mm

0 m 20 m 47

m020 m 35 m 50

35 m 45 m 52

45 m 50 m no restrictor

N.B.: the diameter of the hole is stamped

on the restrictor

No restrictor is required for back

outlet ﬂ ue

DOMINA 102

14

A 90° bend (ﬁ g. 15) is supplied for the horizontal connection of air and ﬂ ue gas pipes. This can be angled

towards the chosen wall in degrees of 45°.

3.03 Top Outlet Concentric Flue Connection

3.03.1 Vertical concentric connection

1KWMA31Y

DS

L

125

70

50*

30

95

80

80 -3 mm/m

Ø60 Ø80

70 min.

* = between 10 e 60 mm

190 270

Fig. 15

A vertical connector can be supplied for vertical

discharge with concentric pipes.

The simple mounting and use of double lip gaskets

at the joints makes this an extremely easy and safe

option.

Fig. 14

Concentric

Vertical

Connector

3.03.2 Horizontal concentric connection

L = S = D = 255

DOMINA 102

15

Fig. 16

Notes on concentric horizontal installation

To locate the centre of the hole for passing the pipes

through the wall, refer to ﬁ g. 12b. Bear in mind that

the two concentric pipes must slope downwards

away from the boiler at a rate of about 3 mm/m to

avoid rainwater entering the boiler. The concentric

pipes making up the air - ﬂ ue gas duct must be sealed

with the gasket where they join the boiler (ﬁ g. 16).

Outside, the pipes should protrude from the wall

between 10 and 60 mm (ﬁ g. 16).

Between

10-60mm

3.03.3 Maximum concentric ﬂ ue length

First table below shows the maximum ﬂ ue lengths available for boilers with concentric systems.

For correct calculation remember to include the reduction for bends on second table. Please refer to

3.02 for use of restrictor

Maximum flue lenght permissible 100 mm concentric 125 mm concentric

Vertical Horizontal* Vertical Horizontal*

Domina 102 4 m 3 m 5 m 5 m

Reduction for bend

100 mm concentric bend 90°1 m

100 mm concentric bend 45°0,5 m

125 mm concentric bend 90°0,5 m

125 mm concentric bend 45°,0,25 m

*For horizontal Flueing the reduction for appliance bend or turret are already included.

max. 3 m

max. 4 m

Fig. 17a Fig. 17b

DOMINA 102

16

Fig. 18

Ø80Ø80

AIRFLUE

1

2

3.04 Top Outlet: Two Pipe Flue System

3.04.1 Two pipe connection

Two separate ducts Ø80 for air intake and ﬂ ue gas

discharge can be directly connected to the boiler.

For conversion mount the separate outlet kit 1 to

top outlet (see 3.03)

Insert blanking plate 2

in remaining air intake

Connect ﬂ ue duct to central hole Ø80 and air duct to left or right air intake hole Ø80. Insert blanking

plate 2 in remaining air intake.

A varied selection of accessories for two pipe systems are available from Ferroli (ref. to page 17). Before

installing your system please check via calculation table at 3.04.2 you are not exceeding the maximum

permissible length for the appliance.

IMPORTANT:

Notes on two pipe system installation:

When using the two pipe system the ﬂ ue discharge pipe must have a 25mm air gap when passing through combustible

materials. Where the ﬂ ue discharge pipe passes through the airing space of an airing cupboard it must be protected

by a non combustible guard or expanded metal giving an annular air gap of at least 25mm.

Where the ﬂ ue discharge pipe passes through a wall containing cavity insulation, a non combustible sleeve must

be ﬁ tted. Additionally a gap of 25mm between the sleeve and the insulation should be provided by cutting

back the insulation or packing loose ﬁ ll bead insulation with mineral ﬁ bre. Where the ﬂ ue pipe is run

through an unheated roof space it should be insulated with non combustible insulating material to prevent

condensation. The ﬂ ue pipe should be supported at intervals of not more than 1.8m and the support

should be preferably below a joint.

3.04.2 Two pipe ﬂ ue system

To determine the maximum length of ﬂ ue and air pipe permissible.

The calculation is based on a standard reference resistance of 1 metre of 80 mm horizontal air intake pipe. For

every conﬁ guration of the two-pipe system all components will have a resistance factor based upon this reference.

(I.e. a 90 degree bend ﬁ tted in the ﬂ ue line would attract a resistance factor equivalent to 2.5 Metres of horizontal

80mm pipe). This is expressed as X metres. Each boiler will have a maximum equivalent length of ﬂ ue/air pipe

and this is shown in the table as N metres. Therefore when calculating the proposed ﬂ ue run the equivalent

resistance of every length of pipe and every bend, whether air intake or ﬂ ue discharge is added together to

give an actual total ﬂ ue length. The ﬁ nal ﬁ gure calculated must not exceed the permitted maximum length

(N metres) for each boiler type.

Calculation Routine

1. Identify all the components needed to complete the proposed ﬂ ue/air pipe run.

2. Calculate the sum of all the equivalent lengths (see table at next page).

3. For boilers, which may require a ﬂ ue restrictor, refer to table at page 13 (par. 3.02) to ascertain the correct

size and add this resistance to your total.

4. Check and verify that the total ﬂ ue/air pipe length (ﬂ ow resistance) does not exceed 50 mt. maximum

permitted for Domina 102.

IMPORTANT: Resistance factors apply to standard férroli components only.

DOMINA 102

17

AIR FLUE

Vertical

Horizontal

Vertical

Horizontal

Description

Male-female flue/Air pipe

1 m - Ø 80

Female-female bend

45° Ø 80 m

Male-female bend

90° Ø 80 m

Dscription

Horizontal

flue terminal

Ø 80 mm

Air intake

terminal

Ø 80 mm

Outlet flue/air inlet

for concentric system

Ø 100/60 mm

Pipe fitting for

outlet flue

Ø80 mm

Outlet flue/air inlet

for connection

with split end

Ø 80 mm

1112

1,2 2,2

1,5 2,5

REDUCTION

5

2

4

AIR FLUE

Vertical

Horizontal

Vertical

Horizontal

REDUCTION

12

A

c

e

s

o

r

i

e

s

Ø

8

0

A

c

e

s

o

r

i

e

s

Ø

8

0

Spigot-and-socket

reduction Ø 100/80 mm

0

3.04.2 (continued)

Tab. 1 - Pipes and

ﬁ ttings reduction table

DOMINA 102

18

For further accessories please refer to:

"Flue system manual for room sealed boiler"

Example of calculation for wall inlet/outlet

with 2 pipe system

maximum total ﬂ ue length: 50 metres

Attention:

Remove the ﬂ ue diaphragm.

The ﬂ ue + air Pipes must have a 3% drop away

from the boiler to outside

7 6 325 1

13 m 13 m

Fig. 19

Example of wall inlet/outlet

2 pipe application

Example of roof inlet/outlet

Example of direct roof ﬂ ue outlet

and wall air inlet

3.04.3 Example of other installation with two pipe systems

Fig. 20a

Fig. 20bFig. 20c

REF. N° OF PIECES DESCRIPTION LENGTH OR

REDUCTION

1 1 Air bend 80 mm R/D = 0,75 1,5 m

2 13 Horizontal air pipe 13,0 m

3 1 Air wall terminal 2,0 m

5 1 Flue bend 80 mm R/D = 0,75 2,5 m

6 13 Horizontal ﬂ ue 26,0 m

7 1 Air wall terminal outlet ﬂ ue 5,0 m

TOTAL 50,0 m

DOMINA 102

19

3.05 Connecting the central heating and domestic hot water circuits

Connect to the relevant connections as indicated in ﬁ g. 1. Connect the pressure relief valve discharge pipe

(15mm) to the outside of the building, where possible over a drain. The discharge must be such that it will not

be hazardous to occupants and passers-by or cause damage to external electric components or wiring. The

pipe should be directed towards the wall. To ensure long life, the heating circuit should be correctly sized and

ﬁ tted with all the controls necessary to ensure correct functioning and operation. The differential between

the boiler ﬂ ow and return pipes should not be more than 20°C. You are advised not to use the boiler

with return temperatures of less than 50°C in order to prevent patches of condensation forming, having a

corrosive effect on boiler components.

3.06 Boiler water characteristics

If the water is harder than 18 clarke degrees, the water used should be treated to avoid possible scale in the

boiler caused by hard water or corrosion by aggressive water. It should be remembered that as a result of its

low thermal conductivity, even scale of just a few millimetres thick can lead to considerable overheating of

the boiler walls, resulting in serious problems.

IT IS ABSOLUTELY VITAL THAT THE WATER USED IS TREATED IN THE FOLLOWING CASES:

a) Extensive systems (containing large quantities of water);

b) Frequent additions of water to top-up the system;

c) Domestic hot water circuits

If the system requires partial or total emptying, you are recommended to reﬁ ll it with treated water.

3.07 Filling

When cold, system pressure should be about 1 bar. If while running venting off of air dissolved in the water causes

the pressure of the central heating system to drop below 0.5 bar, the user must utilise a ﬁ lling loop to bring it

back to the original value. During operation, water pressure in the boiler when hot should be about 1.5 - 2 bars.

After ﬁ lling, always close and disconnect the ﬁ lling loop.

Note - If there is a possibility of air pockets forming in certain points of the central heating system ﬂ ow and return

pipes, you are recommended to ﬁ t an air vent valve at these points.

Note - When the boiler is installed below the level of the central heating a system, single check valve should be

ﬁ tted in the ﬂ ow to prevent gravity circulation around the heating system.

3.08 Gas connection

Gas connection should be carried out using a rigid pipe.

The ﬂ ow at the gas meter should be sufﬁ cient for the simultaneous use at full gas rate of all appliances

connected to it. Connect the gas supply to the boiler according to current regulations. The diameter of

the gas tube leaving the boiler is not the determining factor in choosing the diameter of the pipe between

the appliance and the meter. This must be selected in relation to length and pressure drop and in any

instance should not be less than 22mm.

The whole of the gas installation including the meter should be inspected and tested for soundness and

purged in accordance with BS6891-1988.

N.B. - The ﬁ lling loop will be ﬁ tted by the installer at the time of installing the system. It is NOT a

part of the boiler.

3.09 Electrical connection

The boiler must be connected to a single phase 230 V 50 Hz electricity supply with a 3 A max. fuse and a bipolar

switch with contact opening of at least 3 mm ﬁ tted between the boiler and the electricity supply. The boiler must

always be connected to an efﬁ cient earth installation. Under the electrical box, there is a 3 pole terminal block for

connecting the boiler to the mains (230 V 50 Hz) and a 2 pole board for connecting a room thermostat (RT). To connect,

undo the screws ﬁ xing the terminal block box and connect the wires, ensuring correct polarity of the terminals. It

should be noted that there is low voltage (24 V) between the room thermostat contacts.

DOMINA 102

20

When the boiler is connected to an electricity main, it is essential TO OBSERVE CORRECT POLARITIES (LIVE:

brown cable, NEUTRAL: blue cable, EARTH: yellow-green cable).

All wiring must conform to current I.E.E. regulations.

Note: If the power supply cable has to be replaced, use “0.75mm (24/0.20) heat resisting cable only to

BS6500 with a maximum external diameter of 8 mm.

Note - When connecting a room thermostat or external timer, do not link the power supply of these devices

to the switching contacts. The switch contacts must be voltage free. Any mains powered devices must utilise

mains power solely to drive the timer motor.

Applying mains voltage to the switch contacts will irreparably damage the circuit board.

Although this boiler can also be used without a room thermostat, you are recommended to install one

for the following reasons:

Greater comfort conditions due to more accurate control of room temperature.

Greater energy savings.

3.10 Differential air pressure switch (ﬁ g. 2 - part 43)

The differential air pressure switch is a safety device which allows the main burner to ignite only after having

veriﬁ ed that the fan is working correctly. If the difference in pressure between the ﬂ ue gas discharge pipe and the

air intake pipe is not at least equal to the minimum pressure switch calibration value, the pressure switch contacts

do not close and the gas valve is thus prevented from opening.

In addition, the electrical circuit of the boiler is designed so that if for any reason the air pressure switch contacts

remain closed when the fan stops, the burner will not start up again.

3.11 Checks

Fill the central heating system as described previously (3.07) and check there are no leaks in the domestic hot

water and boiler water circuits. Check that there are no gas leaks on the boiler or the supply to the boiler. Also

check that the electrical connections are correct.

3.12 Installing a room thermostat (72) (ﬁ g. 21b)

To connect the thermostat:

Open the electrical box on the base of the appliance and remove the “jumper cable” between terminals

3 and 4.

Connect the room thermostat (72) as shown in ﬁ gure 21b.

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